Process for production of a borohydride compound

ABSTRACT

A process for production of a borohydride compound M(BH 4 ) y . The process has three steps. The first step combines a compound of formula (R 1 O) y M with aluminum, hydrogen and a metallic catalyst containing at least one metal selected from the group consisting of titanium, zirconium, hafnium, niobium, vanadium, tantalum and iron to produce a compound of formula M(AlH 3 OR 1 ) y , wherein R 1  is phenyl or phenyl substituted by at least one alkyl or alkoxy group; M is an alkali metal, Be or Mg; and y is one or two; wherein the catalyst is present at a level of at least 200 ppm based on weight of aluminum. The second step combines the compound of formula M(AlH 3 OR 1 ) y  with a borate, boroxine or borazine compound to produce M(BH 4 ) y  and a byproduct mixture containing alkali metal and aluminum aryloxides. The third step separates M(BH 4 ) y  from the byproduct mixture.

This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/317,950 filed on Mar. 26, 2010.

This invention was made with Government support under Contract No. DE-FC36-05GO15053 awarded by the Department of Energy. The Government has certain rights in this invention.

BACKGROUND

This invention relates generally to a process for production of a borohydride compound.

Production of sodium borohydride from NaAl(CH₃OCH₂CH₂O)₂H₂ and tris(n-butoxy)boroxine is described in JP 4292401. However, this reference does not disclose the integrated process claimed herein.

The problem addressed by this invention is to find an efficient and economical process for production of a borohydride compound.

STATEMENT OF INVENTION

The present invention is directed to a process for production of a borohydride compound M(BH₄)_(y). The process comprises steps of: (a) combining a compound of formula (R¹O)_(y)M with aluminum, hydrogen and a metallic catalyst comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, niobium, vanadium, tantalum and iron to produce a compound of formula M(AlH₃OR¹)_(y), wherein R¹ is phenyl or phenyl substituted by at least one alkyl or alkoxy group, M is an alkali metal, Be or Mg; and y is one or two; wherein the catalyst is present at a level of at least 200 ppm based on weight of aluminum;

(b) combining the compound of formula M(AlH₃OR¹)_(y) with a borate, boroxine or borazine compound to produce M(BH₄)_(y) and a byproduct mixture containing sodium and aluminum aryloxides; and (c) separating M(BH₄)_(y) from the byproduct mixture.

DETAILED DESCRIPTION

All percentages are weight percentages (“wt %”) and temperatures are in ° C., unless specified otherwise. An “alkyl” group is a saturated hydrocarbyl group having from one to twelve carbon atoms in a linear, branched or cyclic arrangement. Preferably, alkyl groups are acyclic; alternatively C₁-C₆ acyclic. An “aryl” group is an aromatic hydrocarbyl group having from six to ten carbon atoms, and optionally, alkyl and/or alkoxy substituents. An “aralkyl” group is an alkyl group substituted by an aryl group, e.g., a benzyl group. A “borohydride compound” is a compound of formula M(BH₄)_(y), wherein M is an alkali metal, Be or Mg.

Preferably, M is an alkali metal, preferably the alkali metal is lithium, sodium or potassium; preferably sodium or potassium; preferably sodium.

Preferably, R¹ is phenyl or phenyl substituted by at least one of: (i) an alkoxy group having from one to six carbon atoms; and (ii) an alkyl group having from three to six carbon atoms. Preferably, R¹ is phenyl or phenyl substituted by at least one of: (i) an alkoxy group having from one to four carbon atoms; and (ii) an alkyl group having from three to four carbon atoms. Preferably, R¹ is not phenyl or phenyl substituted by methyl. Preferably, R¹ is phenyl substituted by at least one of: (i) an alkoxy group having from one to four carbon atoms; and (ii) an alkyl group having from three to four carbon atoms. Preferably, R¹ is phenyl substituted by an alkoxy group having from one to four carbon atoms, preferably methoxy or ethoxy, preferably methoxy. Preferably, R¹ is 4-methoxyphenyl; 2-methoxyphenyl; 3-methoxyphenyl; 4-ethoxyphenyl; 2-ethoxyphenyl; 3-ethoxyphenyl; 4-isopropylphenyl; 2-isopropylphenyl; 3-isopropylphenyl; 2,6-di-t-butyl-4-methylphenyl; 2,6-di-t-butyl-4-methoxyphenyl; 2,6-di-t-butyl-4-ethylphenyl; 2,4-di-t-butylphenyl; 2,5-di-t-butyl-4-methoxyphenyl; or 2,6-di-isopropylphenyl. Preferably, R¹ is 4-methoxyphenyl; 2,6-di-t-butyl-4-methylphenyl; or 2,6-di-t-butyl-4-methoxyphenyl; preferably 4-methoxyphenyl.

The reaction of a compound of formula (R¹O)_(y)M with aluminum, hydrogen and a metallic catalyst is illustrated in the following equation, in which R¹ is 4-methoxyphenyl, M is sodium and the metallic catalyst is titanium:

Preferably, the metallic catalyst comprises titanium, zirconium, hafnium or combinations thereof; preferably titanium. Preferably, the metallic catalyst is incorporated into the aluminum at a level of at least 240 ppm based on weight of aluminum, preferably at least 280 ppm, preferably at least 300 ppm, preferably at least 320 ppm, preferably at least 340 ppm. Preferably, the metallic catalyst is incorporated into the aluminum at a level no greater than 10,000 ppm based on weight of aluminum, preferably no greater than 5,000 ppm. Preferably, the metallic catalyst may be added as a compound of the metal at the same levels stated above. When the metallic catalyst is titanium, it may be added as an alloy in the aluminum, as a compound of titanium such as titanium(IV) isopropoxide or titanium(IV) chloride or as free titanium metal. Preferably, the mole ratio of aluminum to R¹ OM is at least 0.9:1, preferably at least 0.95:1, preferably at least 1:1; preferably the ratio is no greater than 2:1, preferably no greater than 1.5:1, preferably no greater than 1.2:1. When y is two, these mole ratios would be double the aforementioned numbers. However, when the reaction is carried out with flow of other reactants through aluminum in a fixed bed, one skilled in the art will understand that the amount of aluminum present in relation to the reaction solution in the bed will be much larger. Preferably, the aluminum has an average particle size from 50 to 1000 microns, preferably from 75 to 700 microns. Preferably, the reaction of a compound of formula (R¹O)_(y)M, wherein M is an alkali metal, Be or Mg, with aluminum, hydrogen and a metallic catalyst proceeds under an absolute pressure of at least 300 psi (2 MPa), preferably at least 500 psi (3.4 MPa), preferably at least 700 psi (4.8 MPa). Preferably, the reaction proceeds at a pressure no greater than 1500 psi (10.3 MPa), preferably no greater than 1200 psi (8.3 MPa). Preferably, the reaction proceeds at a temperature of at least 90° C., preferably at least 110° C., preferably at least 130° C., preferably at least 150° C. Preferably, the reaction proceeds at a temperature no greater than 200° C., preferably no greater than 180° C., preferably no greater than 170° C.

The reaction of (R¹O)_(y)M with aluminum and hydrogen in the presence of a metallic catalyst may proceed in a solvent or as a slurry reaction. Solvents suitable for the reaction of (R¹O)_(y)M with aluminum and hydrogen in the presence of a metallic catalyst include ethers, e.g., diglyme, tetraglyme, diethyl ether, dibutyl ether, dibutyl diglyme, tetrahydrofuran, dimethoxyethane, and 2-methyltetrahydrofuran; and aromatic solvents, e.g., benzene, toluene and xylenes. The concentration is not critical, although it is preferred that the (R¹O)_(y)M is dissolved completely in the solvent. The same solvents would be suitable for a slurry reaction.

The compound M(AlH₃OR¹)_(y) is combined with a borate, boroxine or borazine compound to produce an alkali metal borohydride; preferably a borate or boroxine compound. Preferably, the borate or boroxine compound is a boroxine having formula B(OR²)₃ or (R²OBO)₃, wherein R² is aryl or aralkyl; preferably a boroxine where R² is aryl. When M(AlH₃OR¹)_(y) reacts with a boroxine or borazine and y is one, preferably the molar ratio of MAlH₃OR¹ to boroxine is from 3.5:1 to 4.5:1, preferably about 4:1; when y is two, the molar ratios would be half of the aforementioned. Preferably, R² is aryl. Preferably, R² is the same as R¹. This reaction is illustrated in the following equation, in which R¹ and R² are 4-methoxyphenyl, M is sodium and the reactant is a boroxine:

4Na[CH₃OC₆H₄OAlH₃]+(CH₃OC₆H₄OBO)₃→3NaBH₄+3CH₃OC₆H₄OAlO+Na[Al(OC₆H₄OCH₃)₄]

The aluminum-containing products formed along with the borohydride may be more complex than indicated by this equation and may be accompanied by alkali metal aryloxides. This reaction also proceeds with the corresponding triaryl borate, (4-CH₃OC₆H₄O)₃B. Preferred solvents for this reaction are those in which the alkali metal borohydride has limited solubility, e.g., ethers, including 2-methyl-tetrahydrofuran, tetrahydrofuran, dimethoxyethane, diglyme, triglyme, tetraglyme, diethyl ether, dibutyl ether and dibutyl diglyme; aromatic solvents; and alkanes. Especially preferred solvents include 2-methyl-tetrahydrofuran, tetrahydrofuran and dimethoxyethane. Preferably, this reaction proceeds at a temperature in the range from 0° C. to 50° C., preferably from 10° C. to 35° C. Preferably, the alkali metal borohydride precipitates from the reaction solvent and is separated, while the aryloxide salts remain in solution.

The compound M(AlH₃OR¹)_(y) may contain varying amounts of other related species having the formula M(AlH_(4-x)(OR¹)_(x))_(y), where x is an integer from zero to four. Varying amounts of M(AlH₄)_(y) may be present. Species in which x is equal to zero, two or three are also reactive with boroxines or borates. However, it is preferred that the ratio of aluminum to aryl oxide (OR¹) is from 0.5 to 2, preferably from 0.7 to 1.5, preferably 0.8 to 1.2.

Preferably, the aryl oxide species containing alkali metal and/or aluminum which are formed along with the alkali metal borohydride are separated from the borohydride and treated with water or an aqueous acid, preferably a mineral acid, to regenerate the phenol or substituted phenol, R¹OH for recycling. Preferred aqueous acids include sulfuric acid and hydrochloric acid. The recovered phenol may be recycled to form the borate or boroxine and/or to form the (R¹O)_(y)M starting material for M(AlH₃OR¹)_(y). The phenol or substituted phenol may be combined with boric acid (or meta-boric acid or boron oxide) or a trialkyl borate to form a triaryl borate, (ArO)₃B, or triaryl boroxine, (ArOBO)₃, depending on the stoichiometry and temperature of the reaction; higher temperatures and 1:1 stoichiometry between the boron compound and the alcohol or phenol favor the boroxine. Preferably, the reaction temperature is from 100° C. to 300° C., preferably from 110° C. to 250° C., preferably from 110° C. to 200° C., The reaction to form the boroxine is illustrated below for the case where the substituted phenol is 4-methoxyphenol, which reacts with boric acid

Borazines may be generated from the reaction of phenols having an ortho-amino substituent with boric acid or trialkyl borates.

A solvent may be used to separate the borohydride product. Suitable solvents are those in which the borohydride compound is soluble and which are relatively unreactive with borohydride. A solvent in which the borohydride compound is soluble is one in which the borohydride compound is soluble at 25° C. at least at the level of 2%, preferably, at least 5%. Preferred solvents include liquid ammonia, alkyl amines (primary and secondary), heterocyclic amines, alkanolamines, alkylene diamines, glycol ethers, amide solvents (e.g., heterocyclic amides and aliphatic amides), dimethyl sulfoxide and combinations thereof. Preferably, the solvent is substantially free of water, e.g., it has a water content less than 0.5%, more preferably less than 0.2%; with the exception that concentrated (30-45%) aqueous alkali metal hydroxide solution may be used due to the known stability of borohydrides in this medium, e.g., sodium or potassium hydroxide at approximately 40%. Especially preferred solvents include ammonia, C₁-C₄ mono-alkyl amines, pyridine, 1 methyl-2-pyrrolidone, 2-aminoethanol, ethylene diamine, ethylene glycol dimethyl ether, diethylene glycol dimethyl ether, triethylene glycol dimethyl ether, tetraethylene glycol dimethyl ether, dimethylformamide, dimethylacetamide, dimethylsulfoxide and combinations thereof.

The reaction may also be run without a solvent, e.g., as a slurry process or by grinding the solid reactants. Grinding of the reactants will accelerate the reaction, and may be achieved using any method which applies energy to solid particles to induce a mechanochemical reaction, especially any method which reduces solids to the micron size range, preferably the sub-micron size range, and continually exposes fresh surfaces for reaction, e.g., impact, jet or attrition milling. Preferred methods include ball milling, vibratory (including ultrasonic) milling, air classifying milling, universal/pin milling, jet (including spiral and fluidized jet) milling, rotor milling, pearl milling. Especially preferred methods are planetary ball milling, centrifugal ball milling, and similar types of high kinetic energy rotary ball milling. Preferably, milling is performed in either a hydrogen atmosphere, or an inert atmosphere, e.g., nitrogen. In an embodiment in which a solvent is used, grinding of the reactants may be achieved using any method suitable for grinding a slurry. A solvent facilitates heat transfer, thereby minimizing hot spots and allowing better temperature control. Recycle of the solvent is possible to improve process economics. Examples of solvents suitable for use during the process include amines, especially tertiary amines; alkanes and cycloalkanes, especially C₈-C₁₂ alkanes and cycloalkanes; ionic liquids; liquid crown ethers; and for lower-temperature reaction conditions, toluene, glymes and ethers. Suitable reaction solvents are those in which the borohydride compound is soluble and which are relatively unreactive with borohydride.

Another method to accelerate the reaction is to use radiation techniques alone or in combination with reactive milling. For example, microwave irradiation can direct energy at specific reaction surfaces to provide rapid heating and deep energy penetration of the reactants. Microwave absorbers such as metal powders, which could be used as milling media, and dipolar organic liquids may also be added to the reaction system to promote the reaction. The advantage of these techniques is that high reaction rates may occur at considerably lower processing temperature than could be obtained with resistive heating thermal techniques.

In some embodiments of the invention, M(BH₄)_(y) is produced directly by reaction of (R¹O)_(y)M, aluminum, hydrogen and a borate or boroxine compound. Preferably, a boroxine compound is used as a starting material. Preferably, the reaction is carried out in a solvent. Preferably, this reaction proceeds at a temperature in the range from 90° C. to 180° C., preferably from 120° C. to 160° C. and under an absolute pressure of at least 700 psi (4.8 MPa), preferably at least 800 psi (5.5 MPa), preferably at least 900 psi (6.2 MPa). Preferably, the reaction proceeds at a pressure no greater than 5000 psi (34.4 MPa), preferably no greater than 2000 psi (13.7 MPa). Preferably, this reaction occurs in the presehce of a metallic catalyst comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, niobium, vanadium and scandium. Preferably, the catalyst levels are as stated earlier in connection with the reaction of (R¹O)_(y)M with aluminum and hydrogen to form M(AlH₃OR¹)_(y). Preferably, a borate or boroxine compound used for the direct reaction has formula B(OR¹)₃ or (R¹OBO)₃. Preferably, the aryl oxide species containing alkali metal and/or aluminum which are formed along with the alkali metal borohydride are separated and treated as described above to recycle R¹OH.

EXAMPLES

Preparation of Sodium Trihydridoaluminum-(4-methoxy)phenoxide (STAMP): Under an inert atmosphere, 20 g (0.137 mol) of sodium 4-methoxyphenoxide in 100 g (113 mL) of tetrahydrofuran was added to a 300 mL high pressure reactor. Aluminum metal powder (11 g, 0.40 mol) containing 0.185% Ti was added and the reactor sealed. The reactor was then heated to 160° C. and 1000 psi (6.9 MPa) of hydrogen gas was applied. After 15 min the uptake of hydrogen had ceased and the reactor was cooled and the solution filleted under an inert atmosphere to remove excess aluminum, leaving a tetrahydrofuran solution containing 1.09 M of active hydride. Active hydride is hydride that is reactive to form hydrogen. Preparation of Stamp Using Homogeneous Titanium Catalyst: Under an Inert Atmosphere, an anhydrous solution of 20 weight percent sodium 4-methoxyphenoxide in tetrahydrofuran was prepared. 0.1975 g of titanium tetra(n-butoxide) (0.00058 moles) was added to a 100 g portion of 20 weight percent sodium 4-methoxyphenoxide in tetrahydrofuran. 38.62 g of the titanium containing solution was then mixed with an additional 61.41 g of 20 weight percent sodium 4-methoxyphenoxide in tetrahydrofuran. The final solution was added to a 300 mL high pressure reactor. Aluminum metal powder (20 g, 0.74 mol) was added and the reactor sealed. The reactor was then pressurized to 650 psig (4.4 MPa) with hydrogen and heated to 160° C. At 160° C. the pressure was maintained at 915-925 psig (6.31-6.38 MPa) by addition of hydrogen as required. The uptake of hydrogen was initially very gradual, but increased with time. After about 450 min the uptake of hydrogen had ceased and the reactor was cooled and the solution filtered under an inert atmosphere to remove excess aluminum. The hydrogen uptake based on integration of the mass flow controller flow rate was 0.17 moles (theoretical 0.20 moles). The recovery of solids, mainly aluminum metal, was 15.78 g (0.156 moles consumed, theoretical 0.137 moles). Solution hydrolysis gave 0.44 moles of hydrogen (theoretical 0.41 moles), corresponding to 1.3 M NaAlH₃(OR) solution. Attempted Preparation of Sodium Trihydridoaluminum-(4-methoxy)phenoxide without Titanium: Under an inert atmosphere, 25 g (0.171 mol) of sodium 4-methoxyphenoxide in 100 g (125 mL) of tetrahydrofuran was added to a 300 mL high pressure reactor. Aluminum metal powder (11 g, 0.40 mol) was added and the reactor sealed. The reactor was then heated to 180° C. and 1000 psi (6.9 MPa) of hydrogen gas was applied. After 4.5 h, no uptake of hydrogen was observed and the reactor was cooled and the solution filtered under an inert atmosphere to remove excess aluminum, leaving a tetrahydrofuran solution containing unreacted sodium 4-methoxyphenoxide and unreacted aluminum powder.

Effect of Ti Concentration-Addition of Soluble Ti

total g mmoles Example NaMEHQ g Al mg Ti (H₂) % active Number (mol) (mol) added ppm Ti conversion hydride 1 20.1 20.0 0 0 36.7 152 (0.137) (0.743) 2 20.0 10.0 1.4 140 18.2 75 (0.137) (0.371) 3 11.0 10.0 2.8 280 89.5 203 (0.075) (0.371) 4 10.4 20.0 8.6 430 100.0 276 (0.071) (0.742) 5 20.0 20.0 11 550 100.0 436 (0.137) (0.742) 6 12.0 10.0 22 2200 100.0 247 (0.082) (0.370) Note: ppm Ti is relative to the amount of Al Examples 1-6 were prepared by loading the aluminum metal (600 μm average particle size granules, <50 ppm Ti), sodium 4-methoxyphenol and 100 g (88.9 mL) tetrahydrofuran into a 300 mL high pressure reactor along with sufficient titanium(IV) butoxide to provide the amount of titanium specified in the table. The reactor was sealed, initially pressurized to 600 psig with hydrogen, then heated to 160° C. while adjusting the hydrogen pressure so that once at temperature, a reactor pressure of 925 psig was maintained. Upon completion of the reaction, the reactor was cooled and the solution filtered under inert atmosphere to remove insolubles, leaving a tetrahydrofuran solution containing the total moles of active hydride specified.

Example 1 demonstrates that soluble hydride is produced in the absence of added titanium, however, at a low level and at low rates. In addition to the soluble product, sodium hydride (NaH) was observed at 5.4% in the unreacted aluminum, which accounts for some portion of the hydrogen conversion. Example 2 has a lower degree of hydrogen conversion relative to Example 1, however, no sodium hydride was observed in the reaction insolubles. The higher conversion found in Example 1 is most likely a result of NaH formation. The remaining examples produce much higher conversion than in Example 2 and similarly, no NaH was observed in the insoluble, unreacted aluminum.

Preparation of Sodium Borohydride: Under an inert atmosphere, 2.3 g (5.1 mmol) of tri(4-methoxyphenoxy)-boroxine was dissolved in 15 g of 2-methyl-tetrahydrofuran (2-MeTHF). The resulting solution was then added dropwise over 15 min to 50.5 g of a magnetically stirred 2-MeTHF solution of 7.84 wt % sodium trihydridoaluminium-(4-methoxy)phenoxide (STAMP) (22.5 mmol, 1.1 equiv.) in a 100 mL Schlenk flask. During the addition, a white precipitate formed and the flask warmed. The slurry was agitated for an additional 15 minutes, then the stirring was halted and the flask was left to sit overnight to cool and allow the solids to settle. The solids were then filtered, washed with 10 mL 2-MeTHF and dried under vacuum. ¹¹B and ²⁷Al NMR confirmed that the white solids were clean sodium borohydride. Yield: 0.537 g (14.2 mmol, 93%). Purity by hydrogen evolution: 99.6%. Recovery of 4-methoxyphenol (MEHQ): Under an inert atmosphere, 18.1 g of the white byproduct from the reaction to form sodium borohydride (77.3% MEHQ based on reagent input into the sodium borohydride reaction, 14.0 g, 113 mmol) was treated with 70 g of nitrogen-sparged deionized water and the resulting slurry allowed to stir for 10 min. Under positive nitrogen purge, 29.1 g of 1N aqueous hydrochloric acid solution was added stepwise to the slurry to adjust the pH to 7.00. 45 g of methyl isobutyl ketone (MIBK) was then added to the stirred slurry and the resulting mixture filtered in air. The filter cake was washed with 2×15 mL deionized water followed by 3×15 g MIBK. The collected filtrate was transferred to a separatory funnel and the upper, organic layer was collected in a 250 mL Schlenk flask. The aqueous layer was washed with 2×25 g MIBK and the combined organic fractions were vacuum evaporated to give an off-white powder. ¹H NMR confirmed that the collected solids were high purity MEHQ. Yield: 13.6 g (110 mmol, 97%). Preparation of tris(4-methoxyphenoxy)-boroxine: To a 250 mL stirred, two-neck round bottom flask, 61.83 g (1.0 mol) of ortho-boric acid and 130.3 g (1.05 mol) 4-methoxyphenol were added. The flask was fitted with a short path distillation column on one neck and a thermocouple and inert gas needle on the other. The reactor was flushed with nitrogen and the temperature was raised to 120° C., at which time water was generated. After 1 hour, the temperature was raised to 160° C. and held for another hour. After water was no longer observed, the temperature was set to 180° C. A vacuum was then applied to remove the excess 4-methoxyphenol, leaving tris(4-methoxyphenoxy)-boroxine (149 g (0.33 mol)). 

1. A process for production of a borohydride compound M(BH₄)_(y); said process comprising steps of: (a) combining a compound of formula (R¹O)_(y)M with aluminum, hydrogen and a metallic catalyst comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, niobium, vanadium, tantalum and iron to produce a compound of formula M(AlH₃OR¹)_(y), wherein R¹ is phenyl or phenyl substituted by at least one alkyl or alkoxy group and M is an alkali metal, Be or Mg; wherein the catalyst is present at a level of at least 200 ppm based on weight of aluminum; (b) combining the compound of formula M(AlH₃OR¹)_(y) with a borate, boroxine or borazine compound to produce M(BH₄)_(y) and a byproduct mixture containing alkali metal and aluminum aryloxides; and (c) separating M(BH₄)_(y) from the byproduct mixture.
 2. The process of claim 1 in which M is lithium, sodium or potassium, and y is one.
 3. The process of claim 2 in which R¹ is phenyl substituted by an alkoxy group having from one to four carbon atoms.
 4. The process of claim 3 in which said at least one metal is titanium.
 5. The process of claim 4 in which M is sodium and R¹ is 4-methoxyphenyl.
 6. The process of claim 1 in which said borate, boroxine or borazine compound is a borate or boroxine compound which has formula B(OR¹)₃ or (R¹OBO)₃.
 7. The process of claim 6 further comprising combining the byproduct mixture with water or an aqueous acid to generate R¹OH.
 8. The process of claim 7 further comprising combining R¹OH with boric acid, meta-boric acid, boron oxide or a trialkyl borate to form a borate or boroxine compound of formula B(OR¹)₃ or (R¹OBO)₃.
 9. The process of claim 8 in which R¹OH generated by combining the byproduct mixture with water or an aqueous acid is used to form R¹OM, which is then combined with aluminum, hydrogen and a metallic catalyst comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, niobium, vanadium, tantalum and iron to produce a compound of formula MAlH₃OR¹; and in which M is sodium and R¹ is phenyl substituted by an alkoxy group having from one to four carbon atoms.
 10. A process for production of a borohydride compound M(BH₄)_(y) directly by contacting (R¹O)_(y)M, aluminum, hydrogen and a borate or boroxine compound; wherein R¹ is phenyl or phenyl substituted by at least one alkyl or alkoxy group; M is an alkali metal, Be or Mg; and y is one or two. 